Three-piece disposable undergarment

ABSTRACT

A disposable undergarment includes a front body panel having a pair of opposite first side edges, a first waist edge and a first crotch edge spaced from said first waist edge. A rear body panel has a pair of opposite second side edges, a second waist edge and a second crotch edge spaced from said second waist edge. The crotch edges of each of the front and rear body panel webs includes at least one peak and at least one valley. Each of the front and rear body panels have a minimum rise defined between the valley of each of the respective front and rear body panels and the first and second waist edges respectively. The valleys defining the minimum rises form at least in part leg opening portions of the front and rear body panels. The crotch edges of the front and rear body panels are spaced apart and form a gap therebetween in a non-overlapping relationship. A crotch member bridges the gap and has opposite end portions connected to the front and rear body panels respectively. The crotch member does not cover the valleys defining the minimum rises of each of the front and rear body panels.

This application is a divisional of U.S. application Ser. No.11/330,422, filed Jan. 11, 2006, now U.S. Pat. No. 7,419,562 which is acontinuation of U.S. application Ser. No. 10/452,299, filed Jun. 2,2003, which is a continuation-in-part of U.S. application Ser. No.10/261,805, filed Oct. 1, 2002, now U.S. Pat. No. 6,979,380 the entiredisclosures of which are hereby incorporated herein by reference.

BACKGROUND

The present invention relates generally to disposable undergarments, andin particular, to a three-piece undergarment having a folded crotchmember and to the method for the manufacture thereof from a nested frontand rear body panel web.

Disposable undergarments can be configured in many different forms. Forexample, disposable absorbent garments can be configured as a pant-type,pull-on garment, or as a diaper-type product that is drawn up betweenthe legs and fastened about the waist with various fastening systems.Often, absorbent garments include an outer cover, which forms at least apart of a body panel that is secured around the waist of the user. Inaddition, the outer cover typically extends along a crotch region of thegarment.

Often, the outer cover is made from a single piece of material, with legopenings cut therein, for example by die cutting. The material from theleg cut out, which can account for as much as 20-30% of the total areaof the outer cover, typically is waste material, which must be disposedof or recycled. In addition, the size of the leg openings formed by adie cutter in a conventional one-piece outer cover is typically fixed.As such, it can be expensive and time consuming, and reduces the overallflexibility of the manufacturing line, to switch dies and alter theprocess to manufacture different size garments.

In response to this problem of waste, some garments are configured withfront, rear and crotch sections formed from a single web that is dividedinto two nested halves, as disclosed for example in U.S. Pat. No.5,858,151 and Japanese Patent Application 03-176053 A. However, the websof the U.S. Pat. No. 5,858,151 have overlapping crotch portions that aredirectly secured one to the nested halves, as disclosed for example inU.S. Pat. No. 5,858,151 and Japanese Patent Application 03-176053 A.However, the webs of the U.S. Pat. No. 5,858,151 have overlapping crotchportions that are directly secured one to the other. Accordingly, theoverall rise of the garment is not readily varied to accommodatedifferent size users, and the range of sizes is limited by the extent ofthe overlapping regions.

Conversely, the diaper body of Japanese Patent Application 03-176053 Ais positioned over the cut-out portions of a front and back waistband,such that the exposed portion of the waist bands defining in part theleg holes are linear. Instead, the shape of the leg hole is determinedby the cut shape of the diaper body, which produces excess material thatmust be disposed of or recycled.

In addition, crotch members are often secured to the bodyside of thebody panels or integrated therein, rather than being secured to thegarment side thereof. Accordingly, the body panels can restrict theexpansion of the crotch member, for example when an absorbent insert isinsulted by the user.

U.S. Pat. Nos. 6,217,563 and 6,264,641, the entire disclosures of whichare hereby incorporated herein by reference and which are both assignedto Kimberly-Clark Worldwide, Inc., the Assignee of the presentapplication, disclose securing an expandable absorbent composite to agarment side of a pair of spaced apart body panels. The '563 and '641patents disclose that the inboard edges of the body panel are straightor curved, and in one particular arrangement are concave-inward.

In addition, the crotch member, which is often configured as anabsorbent insert, is typically not stretchable. Often, thenon-stretchable crotch member is secured across its entire width, so asto reduce or otherwise impede the elongation of the body panel andthereby adversely affecting its ability to conform to the body of theuser.

Therefore the need remains for improved methods and assemblies formanufacturing undergarments to reduce the waste of materials whileproviding improved comfort for the user and flexibility in manufacturingdifferent size garments.

SUMMARY

Briefly stated, in one embodiment described below, a disposableabsorbent garment includes a front body panel having a first bodysidesurface, a first garment side surface, a pair of opposite first sideedges, a first waist edge and a first crotch edge defining a first lobehaving a first profile in plan view that extends outwardly relative tothe first waist edge. The first lobe has a first maximum rise along afirst direction at substantially a centerline of the front body panel.The opposite first side edges are spaced along a second direction, withthe second direction being substantially perpendicular to the firstdirection. A rear body panel has a second bodyside surface, a secondgarment side surface, a pair of opposite second side edges, a secondwaist edge and a second crotch edge defining a second lobe having asecond profile in plan view that extends outwardly relative to thesecond waist edge. The second lobe has a second maximum rise along thefirst direction at substantially a centerline of the rear body panel.The opposite second side edges are spaced along the second direction.The first lobe of the front body panel is aligned with the second lobeof said rear body panel. A crotch member includes a base panel havingopposite side edges and at least a pair of folds extending from the sideedges of the base panel. The pair of folds are connected to the firstand second garment side surfaces of the front and rear body panelsrespectively. The crotch member is aligned with and overlaps the firstand second lobes of the front and rear body panels respectively on thefirst and second garment sides thereof.

In one embodiment, the crotch member is substantially C-shaped incross-section. In another embodiment, side portions of the crotch memberare substantially Z-shaped in cross-section.

In one embodiment, the crotch member is formed as an absorbent insert.The absorbent insert includes a top sheet, a back sheet and a retentionportion disposed therebetween.

In another aspect, a method of manufacturing an undergarment includesmoving a web of body panel material in a longitudinal machine directionand cutting the web of body panel material along the longitudinalmachine direction to thereby form a rear body panel web and a front bodypanel web each having a maximum rise and a minimum rise respectively.The maximum rise of each of the rear and front body panel webs isgreater than the minimum rise of a corresponding one of the rear andfront body panel webs. The method further includes shifting at least oneof the rear and front body panel webs in the longitudinal machinedirection and thereby aligning the maximum rises of the rear and frontbody panel webs. The method further includes centering a crotch memberwith the maximum rises of the rear and front body panel webs andconnecting the crotch member to a garment side surface of the front andrear body panels.

In one embodiment, the cutting of the web of body panel material alongthe longitudinal machine direction includes forming a substantiallysinusoidal pattern defining the maximum and minimum rises of each of therear and front body panel webs.

In one embodiment, the front and rear body panel webs are cut along thelateral cross direction proximate the minimum rise of each of the frontand rear body panel webs. Also in one embodiment, the crotch member isfolded.

In another aspect, a die is used to cut the web of body panel material.In one embodiment, the method includes forming a cut edge along each ofthe front and rear body panel webs, wherein the cut edges of the frontand rear body panel webs have a first and second shape respectively. Inone embodiment, the first shape is different than the second shape.

In another aspect, the wave pattern defining the cut edges of the frontand rear body panel webs is not symmetrical relative to a centerlineextending in the longitudinal machine direction. In particular, thecurve defining the cut edge on one side of the centerline has adifferent shape than the curve defining the cut edge on the other sideof the centerline. In one example, the curves, if continuous on bothsides of the centerline, would have a different wavelength.

In another aspect, one embodiment further includes elongating the web ofbody panel material in the longitudinal machine direction before cuttingthe web of body panel web. In this way, the pitch of the garment can beeasily changed simply by varying the amount of elongation introducedinto the web before the web is cut.

In yet another aspect, one embodiment of the method further includesvarying a gap formed between the maximum rises of each of the rear andfront body panel webs. In this way, the overall rise of the garment canbe easily changed simply by varying the gap.

In various embodiments, elastic elements are positioned along one ormore of the outer lateral edges of the inner cut edge of one or more ofthe webs.

In another embodiment, the crotch member is formed of anelastic/stretchable material. In one particular embodiment, one or bothof a top sheet and backsheet, with a retention portion disposedtherebetween, are stretchable and include an elastic material.

In another aspect, a method includes stretching at least one of the backsheet and top sheet. In yet another aspect, a method includesinstructing a user on the user of a disposable undergarment is provided.

The various aspects provide significant advantages over other disposableundergarments and methods. For example and without limitation, thenested body panels of one embodiment maximize the area of body coveragewhile minimizing and virtually eliminating the amount of waste material.In addition, by securing the crotch member to the garment side surfaceof the body panels and centering it over the lobes, a unique gasketsystem is created that maintains a close fit of the garment to the bodyof the user while allowing the crotch member, e.g., an absorbent insert,to expand outwardly from the skin. In addition, the lobes of the frontand rear body panels provide a physical barrier between a wet absorbentinsert and the skin of the user.

The foregoing paragraphs have been provided by way of generalintroduction, and are not intended to limit the scope of the followingclaims. The presently preferred embodiments, together with furtheradvantages, will be best understood by reference to the followingdetailed description taken in conjunction with the accompanyingdrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic illustration of a system for manufacturing anabsorbent garment.

FIG. 2 is a plan view of a web of body panel material being cut along alongitudinal machine direction.

FIG. 3 is a plan view of a front and rear body panel web with aplurality of absorbent inserts being applied thereto.

FIG. 4 is a plan view of one embodiment of an absorbent garment in anunfolded configuration.

FIG. 5 is a plan view of another embodiment of an absorbent garment inan unfolded configuration.

FIG. 6 is a plan view of a web of body panel material being cut along alongitudinal machine direction.

FIG. 7 is a plan view of a front and rear body panel web separated inthe cross direction and aligned in the machine direction.

FIG. 8 is a garment having a front and rear body panel web formed fromthe webs shown in FIG. 7.

FIG. 9 is a plan view of another embodiment of an absorbent garment inan unfolded configuration.

FIG. 10 is a cross sectional view of the absorbent garment shown in FIG.9 taken along line 10-10.

FIG. 11 is a cross sectional view of the absorbent garment shown in FIG.9 taken along line 11-11.

FIG. 12 is an alternative cross-sectional view of the absorbent garmentshown in FIG. 9 taken along line 12-12.

DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED EMBODIMENTS

It should be understood that the term “longitudinal,” as used herein,means of or relating to length or the lengthwise direction. The term“laterally,” as used herein means situated on, directed toward orrunning from side to side.

The term “bodyside” should not be interpreted to mean in contact withthe body of the user, but rather simply means the side that would facetoward the body of the user, regardless of whether an undergarment isactually being worn by the user and regardless of whether there are ormay be intervening layers between the component and the body of theuser. Likewise, the term “garment side” should not be interpreted tomean in contact with the garments of the user, but rather simply meansthe side that faces away from the body of the user, and therefore towardany outer garments that may be worn by the user, regardless of whetherthe undergarment is actually being worn by a user, regardless of whetherany such outer garments are actually worn and regardless of whetherthere may be intervening layers between the component and any outergarment.

The term “machine direction” means the direction of flow as the variousmembers and webs progress along the fabrication line and process. Itshould be understood that various separate members or webs can each betraveling in a machine direction, but with the various machinedirections not necessarily being parallel or oriented in the samedirection. For example, a first component such as a web may be travelinga first machine direction, which is substantially perpendicular to thetravel of another component, such as an absorbent insert, in a secondmachine direction.

The term “cross direction” means the direction substantiallyperpendicular to the machine direction.

The term “downstream” means that one item is positioned more closely tothe output or finished product end of the machine and/or processrelative to another item. Conversely, the term “upstream” means that anitem is positioned more closely to the input end of the machine orprocess relative to another item. For example, the output end isdownstream of the input end, and vice versa, the input end is upstreamof the output end.

The phrases “removeably attached,” “removeably attaching,” “removeablyconnected,” “removeably engaged,” “releasably attached,” “releasablyconnected,” or “releasably engaged,” and variations thereof, refers totwo or more elements being connected or connectable such that theelements tend to remain connected absent a separation force applied toone, both or all of the elements, and where the elements are capable ofbeing separated upon the application of a separation force. The requiredseparation force is typically beyond that encountered while wearing theabsorbent garment.

The phrases “fixedly secured,” “fixedly engaged,” “fixedly attached,”“fixedly connected,” and variations thereof, refers to two or moreelements being connected or connectable such that they are notdisconnected or otherwise separated, and are not intended to beseparated or disconnected, during the normal operation and use of theabsorbent garment.

The term “web” refers to a continuous stream of material, whether madefrom one or more layers or substrates, and regardless of whether it mayhave non-continuous, discrete items disposed thereon.

The terms “connecting,” “coupled,” “attached,” and “secured,” andvariations thereof, broadly covers two or more items being directlyconnected one to the other, or by way of one or more intervening membersor components.

Referring to FIGS. 4, 5 and 9, an undergarment 2 includes a first, frontbody panel 4 and a second, rear body panel 6. The term “body panel”refers to the portion(s) of the undergarment, whether made of one ormore layers or substrates or of one or more pieces or components, thatis/are fitted circumferentially around at least the waist region of theuser, including for example the user's lower back, buttock, hips andabdomen. The first and second body panels each have an inner, bodysidesurface 10 and an outer, garment side surface 12. The first, front bodypanel 4 has a first edge 14 forming a crotch portion 16 and leg openingportion 18 and a second terminal edge 20 which, in one embodiment, islinear but can assume other shapes. Likewise, the second, rear bodypanel 6 has a first edge 22 forming a crotch portion 24 and a legopening portion 26 and a second terminal edge 28, which is shown linearbut can assume other shapes. Each of the first and second body panelshas an outboard side edge 30, 32 formed along the outer periphery of theopposite side portions of the first and second body panel. It should beunderstood that the outboard side edges of the front and rear bodypanels can have different lengths relative to each other.

Referring to FIG. 5, one or more, and in one embodiment a plurality,meaning two or more, elastic elements 36 are secured to each of thefirst and second body panels. In preferred embodiment, a plurality ofelastic elements are spaced across substantially the entire waistportion of the front and rear body panel 4, 6, although they may bespaced across a lesser length. For example, elastic elements can extendalong the upper waist portion and along the lower terminal edge definingin part a leg opening 34.

In one embodiment, the front body panel has a “non-elasticized” areawherein there are no elastic elements, or other elastic or elastomericbacking members, incorporated therein or making up any portion of thethickness or cross-section of the body panel at that area. It should beunderstood, that in an alternative embodiment, one or more separatewaist bands, with or without elastic elements, can be secured to one orboth of the rear and front body panels, preferably along the upperterminal edges 20, 28 thereof. Likewise, one or more separate leg bandscan be secured to one or both of the rear and front body panels alongthe leg open portions 18, 26 adjacent the leg openings 34.Alternatively, one or both of the body panels can be formed without anyelastic elements as shown in FIG. 4.

The various waist and leg elastic elements can be formed from rubber orother elastomeric materials. One suitable material is a LYCRA® elasticmaterial. For example, the various elastic elements can be formed ofLYCRA® XA Spandex 540, 740 or 940 decitex T-127 or T-128 elasticsavailable from E.I. duPont De Nemours and Company, having an office inWilmington, Del.

Referring to the embodiments of FIGS. 4, 5, 9, 10 and 12, each bodypanel 4, 6 is formed as a composite, or laminate material, otherwisereferred to as substrates or laminates, with the plurality of elasticstrands or an elastomeric substrate 204 sandwiched therebetween. In oneembodiment, the elastic substrate is made of an elastomeric film ornonwoven elastic or stretchable material including for example but notlimited to styrenic copolymers of polyisoprene, polybutadiene orpolyolefin, copolymers of polyolefins, natural or styrene butadienerubber, polyurethanes, polyamides, polyesters, and co-extrusions/blendsof the aforementioned materials. The elastic substrate or core can beformed as a membrane or from a plurality of elastic strands.

Preferably two or more layers 202 are bonded with various adhesives,such as hot melt, or by other techniques, including for example andwithout limitation ultrasonic bonding and heat pressure sealing. In oneembodiment, the two layers are made of a non-woven material such as aspunbond material, a bonded carded material or other known materials. Itshould be understood that the body panels can be made of a single layeror substrate of non-woven material, or can be comprised of more than twolayers or substrates. Of course, it should be understood that otherknitted or woven fabrics, non-woven fabrics, elastomeric materials,polymer films, laminates and the like can be used to form one or more ofthe body panel layers. The term “non-woven” web or material, as usedherein, means a web having a structure of individual fibers or filamentsthat are interlaid, but not in an identifiable manner and without theaid of textile weaving or knitting, as in a knitted or woven fabric.

In one embodiment, the body panel material can be secured to the elasticelements, such as a elastomeric web, strands or ribbons, which have beenelongated and retracted, such that the material is gathered when theelastic elements are relaxed. Alternatively, the material can begathered and laminated to non-elongated elastic elements. In oneembodiment, the body panel includes a gathered elastic laminate madefrom nonwoven base sheets bonded with elongated elastic element(s)sandwiched therebetween.

In various embodiments, the body panel material may be substantiallypermeable to air or substantially impermeable to air. The body panelmaterial also may be substantially liquid-permeable or substantiallyliquid-impermeable. In particular arrangements, the body panel materialmay be substantially nonelastomeric. In other aspects, the body panelscan include an elastomeric material that is elastomerically stretchableat least along the lateral article width. Examples of such elastomericcomposite materials can include a continuous filament stretch bondedlaminate (CFSBL), a vertical filament laminate (VFL),neck-bonded-laminate (NBL), a stretch-bonded-laminate (SBL), anecked-stretch bonded laminate (NSBL) or a necked-thermal laminate, orthe like, as well as combinations thereof. Exemplary CFSBL, NBL, SBL,and NSBL materials are described in U.S. Pat. Nos. 5,226,992, 4,981,747,4,965,122, 5,336,545, 5,385,775, 5,414,470, 4,720,415, 4,789,699,4,781,966, 4,657,802, 4,652,487, 4,655,760, 5,116,662, 5,114,781 and6,323,389, all of which are hereby incorporated herein by reference.Exemplary VFL materials are described in U.S. Provisional PatentApplication Ser. No. 60/204,307, filed May 15, 2000 and entitled “Methodand Apparatus for Producing Laminated Articles,” and PCT application WO01/88245 A2, both assigned to Kimberly-Clark Worldwide, Inc., theAssignee of the present application, with the entire disclosures of bothbeing hereby incorporated herein by reference. Such laminates canprovide an improved combination of cloth-like feel and elastomericstretchability. The body panels can be composed of materials that areelastic or elastomeric and exhibit biaxial stretch characteristics orMD/CD stretch characteristics, or that are extensible composites.Additional waist and leg elastic elements can be added to, but are notnecessarily required by, the body panels.

In one embodiment, the entirety of the body panels are elasticized, suchthat the entire body panel conforms to the body of the user without anyspacing between the body panel and the user's body, and without theattendant bulkiness of a non-elasticized material.

In various embodiments, the body panels are breathable, cloth-like,multi-directional nonwoven laminates with stretch and/or extensibleproperties. In one embodiment, the non-woven layers are pre-necked, forexample between about 10% and about 80%, in the longitudinal direction,which provides extensibility in the longitudinal direction with minimumforce.

The terms “extensible,” “extensibility,” and variations thereof as usedherein means capable of being extended, and providing a selectedelongation, for example between about 5% and about 70%, when subjectedto an applied tensile force. The body panel also is preferably capableof providing a selected, sustained deformation when subjected to anapplied tensile force and then allowed to relax for a selected timeperiod beginning immediately after removal of the tensile force. Thesustained deformation is a substantially permanent deformation. Theselected elongation and sustained deformation preferably occur at leastalong the longitudinal direction of the garment, although it should beunderstood that it also could occur along the lateral direction, orboth. Various extensible materials, and other acceptable materials thatcan be used for the body panels are described for example in U.S. Pat.No. 6,217,563, issued Apr. 17, 2001 to Kimberly-Clark Worldwide, Inc.,the same Assignee as the present application, the entire disclosure ofwhich is hereby incorporated herein by reference.

The extensibility of the non-woven material provides an increase insurface area without the retractive force of elastomeric materials. Inone embodiment, body panel is extensible in at least thecross-direction, or longitudinal direction, with the material providingan elongation of at least about 1 cm when subjected to a tensile forceof 11.8 grams per cm. In addition, the body panel provides asubstantially permanent deformation of at least about 20% when it issubjected to a tensile force of 19.70 grams per cm and is then allowedto relax under a zero applied stress for a period of 1 minute. Ofcourse, it should be understood that the body panel can also be madeextensible in the lateral direction. A suitable technique for generatinga representative tensile-load v. extension curve, and for determiningthe amount of elongation and/or retractive force parameters of aselected component or material can employ ASTM Standard Test Method D882(Tensile Method for Tensile Properties of Thin Plastic Sheeting) datedDecember 1995, with the following particulars. The “width” of the testsample will be a cross-wise width which can be conveniently obtainedfrom the product being tested, and is desirably about 2 inch (about 5.04cm). The test sample width is perpendicular to the direction of thetensile force applied during the testing. With regard to the shownconfigurations, for example, the test sample “width” generallycorresponds to the length-wise dimension of the component along thelongitudinal direction of the article. The initial separation of thejaws of the tensile tester is 3 inches (7.62 cm), and the moving jaw ismoved at a constant rate of 50 mm/min. The moving jaw is stopped at anextension of 50 mm for a period of 10 sec, and then returned back to itsinitial starting position at a rate of 50 mm/min. The force-extensioncurve to the complete tension and retraction cycle can be recorded on aconventional computer equipped with commercially available software,such as TestWorks for Windows, version 3.09, which is available from MTSSystem Corporation, a business having a location at 14000 TechnologyDrive, Eden Prairie, Minn. The obtained data is normalized and reportedin appropriate units of force per unit length of sample “width” (e.g.grams-force per inch, or Newtons per inch, or grams-force percentimeter, or Newtons per centimeter).

In one embodiment, the front and rear body panels 4, 6 are made ofnon-woven laminates of two layers of longitudinally extensible 0.60 osypolypropylene spunbond material with elongated strands of Lycra® elasticsandwiched between the spunbond layers and thereafter adhesively bonded.In particular, the body panel material is necked in the cross direction.As used herein, the term “necked,” and variations thereof, refers to anymaterial that has been constricted in at least one dimension by applyinga tensioning force in a direction that is perpendicular to the desireddirection of neck-down. Processes that may be used to constrict amaterial in such a manner include, for example and without limitation,drawing processes. The elastics are then elongated in the machinedirection and secured to the body panel material. The elastics are thenallowed to retract so as to gather the necked spunbond material in thelateral (machine) direction thereby creating an elastically gatherednon-woven body panel with longitudinal extensibility. The term “gather,”and variations thereof, as used herein means puckered, or contractedinto folds or wrinkles, which should be understood as includingmicro-pleats.

In this way, the body panel can be elongated in both the longitudinaland lateral direction to conform to the body of the user when thegarment is applied thereto. In particular, as the user pulls the garmentup over their hips, the non-woven laminate body panels stretch in thelateral direction while the leg regions of the front and rear bodypanels conform to the crotch and body lines of the user. At the sametime, the body panel material extends in the longitudinal direction toconform to the buttocks and stomach of the user. The extensibility ofthe body panels follows the natural curvature of user's body to provideconformance thereto. As the body panel extends in the longitudinaldirection, the spacing between the laterally extending elastic elements36, incorporated in one embodiment, will increase.

In one embodiment, the body panel non-woven material is substantiallyhydrophobic, which may optionally be treated with a surfactant orotherwise processed to impart a desired level of wettability andhydrophilicity. In one particular embodiment of the invention, the bodypanel is a nonwoven, wire-weave spunbond polypropylene fabric composedof about 1.6 denier fibers formed into a web having a basis weight ofabout 0.6 osy. One suitable non-woven material is the Corinth 0.60 osy,1.6 dpf wireweave, nonwettable Metallocene (EXXON ACHIEVE 2854 PP)spunbond material manufactured by Kimberly-Clark Corporation, theAssignee of the present application.

Referring to FIGS. 4 and 5, a crotch member 50 connecting the front andrear body panels 4, 6 can be folded such that the side edges 30, 32 ofthe front and rear body panels 4, 6 are aligned wherein they can befixedly secured at a seam. The seam can be formed by bonding, sewing orotherwise attaching the side edges. Alternatively, the product canremain “open,” wherein the body panels are releasably secured with oneor more fastening members as explained below.

In one embodiment the garment includes a combination of side edges thatare secured to form a seam and fastening members that allow the fit ofthe undergarment to be adjusted. For example, fastening members arepreferably attached to the front body panel and extend inboard relativeto the outboard side edge 30 of the front body panel 4 from anattachment location, which is preferably spaced inboard from the sideedge. A landing member can be formed on or secured to the body panel toreceive a refastenable portion of the fastening member. One or morelines of weakness can be provided along the front or rear body panelsuch that one or both of the body panels are breakable. The lines ofweakness can comprise a perforation or other series of cuts, a thinning,breakage or separation of material, or a strip of a different kind ofmaterial bridging portions of the body panel that is more easily torn orbroken than the other material thereof, which allow a user or themanufacturer to separate portions of the body panel. For example, theundergarment can be broken along the lines of weakness after the garmentis applied to a user, or beforehand.

It should be understood that, in other embodiments, the fasteningmembers can be secured to the rear body panel and engage the front bodypanel or, conversely, can be secured to the front body panel and engagethe rear body panel, for example along at least a portion that is notelasticized. In one embodiment, the fastening members are fixedlysecured to the outer, garment-side surface of the front and/or rear bodypanels, and releasably engage the outer, garment-side surface of thefront and/or rear body panels, although it should be understood that thefastening members could be fixedly secured to an inner body-side surfaceof front and/or rear body panels and releasably engage an inner,body-side surface of the front and/or rear body panels.

When incorporated into a disposable absorbent undergarment, in oneembodiment, the fastening members include a refastenable portion, suchas an array of hook members, adhesives, such as pressure sensitiveadhesives, buttons, zippers, snaps and other releasable and reattachablefastening devices. In various embodiments, the fastening member includesone, two or more than two tab members. In one embodiment, the fasteningmembers comprise a carrier member, which is preferably fixedly securedto the side portions of the front body panel with adhesive bonds, sonicbonds, thermal bonds, pinning, stitching or other known types ofattachment. In alternative embodiments, the fastening members can befixedly secured to the rear body panel or to one or both of the frontand rear body panels, for example, at the seam, as explained above.

Referring to FIGS. 4, 5 and 9, in one embodiment the undergarment isdisposable and is also configured as an absorbent undergarment. In theabsorbent garment, the crotch member 50 is configured as an absorbentinsert having first and second opposed terminal end edges 60, 62.

In various embodiments, shown in FIGS. 9-12, the absorbent insert crotchmember 50 preferably includes a substantially liquid permeable topsheet206, or liner, a substantially liquid impermeable barrier layer orbacksheet 208, and an outer cover 210, which is made in one embodimentof a non-woven material that provides a cloth-like feel. The outer covermay be omitted in some embodiments. A retention portion 212 is disposedor sandwiched between the topsheet and the backsheet, which areconnected. The topsheet, backsheet and other components of the absorbentinsert 50 can be joined for example with adhesive bonds, sonic bonds,thermal bonds, pinning, stitching or any other attachment techniquesknown in the art, as well as combinations thereof. For example, auniform continuous layer of adhesive, a patterned layer of adhesive, asprayed pattern of adhesive or any array of lines, swirls or spots ofconstruction bonds may be used to join the topsheet and backsheet, orany of the other components described herein.

It should be understood that the term “absorbent insert” refers to anymaterial or assembly capable of absorbing liquids or bodily exudates,and may be comprised of a single material or component, for example aretention portion, or can be formed as a composite of severalcomponents. It should also be understood that the term “crotch member”refers to any member made of any material, including for example andwithout limitation those described herein with respect to the bodypanels and absorbent inserts, and is not limited to absorbent insertsand/or materials. For example, the crotch member may be made of one ormore layers of a non-woven material.

In one embodiment, additional layers, including for example, a surgelayer, are also preferably incorporated into the absorbent insert.Preferably, the surge layer does not run the entire length of theabsorbent insert and is shorter than the retention portion. The topsheetcan be indirectly joined to the backsheet by affixing the topsheet tointermediate layers, such as the surge layer or retention portion, whichin turn is affixed to the backsheet. The absorbent insert also mayinclude barrier cuffs, or leakage control shields, formed along theopposite longitudinally extending edges of the absorbent composite.

Referring to FIGS. 9-11, the absorbent insert has a base panel 214 and apair of folds 218 extending laterally inward from and joined to the basepanel 214 at opposite folded side edges 216. The pair of folds 218 andbase panel 214 provide the absorbent insert with a C-shape configurationin cross-section. The garment side 226 of the folds are secured to thegarment side 12 of the body panels 4, 6 at an attachment location 220,for example adjacent a free edge 222 of the folds. Referring to FIG. 9,the attachment location can extend continuously and longitudinally alongthe portion of the crotch member that overlaps the front and rear bodypanels, or in other embodiments, the attachment locations can beconfigured as one or more discrete and spaced-apart attachmentlocations.

Referring to FIGS. 9-11, the folds 218 can be formed from anycombination of the top sheet 206, the backsheet 208, the outer cover214, retention portion 212, or any other component. For example, asshown in FIGS. 10 and 11, the folds 218 are formed from a combination ofthe topsheet 206, backsheet 208 and outer cover 214. In otherembodiments, only one of those components, e.g., the backsheet or topsheet, forms the fold, and in other embodiments, some subcombinationthereof forms the folds, for example the outer cover and backsheet butnot the top sheet or retention portion. It should be understood that theretention portion can also include folds that are interfolded with thefolds of the backsheet and top sheet. Each of the individual layers mayalso have an edge folded back over itself.

Referring to FIGS. 10 and 11, one or more longitudinally extendingcrotch elastics 224 are disposed between and secured to the topsheet andbacksheet using various methods described above. The crotch elastics 224extend along the sides of the crotch member and overlap in oneembodiment a portion of the front and rear body panel, as shown in FIG.9. The crotch elastics provide a gasket against the body of the user.

It should be understood that any number of folds can extend from thebase panel. For example, as shown in FIG. 12, the absorbent insert 50includes a pair of first folds 218 extending from opposite first foldededges 216 formed at the juncture with the base panel, and a pair ofsecond folds 230 extending from opposite second folded edges 234 formedat the juncture with the first folds. In this embodiment, a bodysidesurface 232 of the absorbent insert, and in particular the second folds,are secured to the garment side surface 12 of the body panels 4, 6. Aswith the embodiment of FIGS. 9-11, the first and second folds 218, 230can be formed from any combination of the various layers of theabsorbent insert, including the backsheet, the top sheet, the outercover and the retention portion. In addition, crotch elastics 224, whichcan include in various embodiments one or more strands, are disposedbetween two or more of the layers in one or both of the first and secondfolds 218, 230. In the embodiment of FIG. 12, opposite side portions 236of the absorbent insert have a Z-shape in cross-section. It should beunderstood that other embodiments may include more than two folds oneach side of the absorbent insert. For example, each side portion may beformed as a multi-pleated configuration. Alternatively, the absorbentinsert may not have any folds, and may be formed from a single layer,having a body side surface secured to the garment side surface of thebody panels.

The backsheet is preferably liquid impermeable, but may be liquidpermeable, e.g., when an additional barrier layer is used with theretention portion. For example, in one embodiment, the backsheet can bemade from a thin plastic film, or other flexible, substantiallyliquid-impermeable material. As used herein, the term “flexible” means amaterial that is compliant and which will readily conform to the generalshape and contour of the body of the user. The backsheet preventsvarious bodily fluids and exudates from wetting or otherwisecontaminating various bedding or outer garments worn by the user overthe absorbent garment. In particular, the backsheet can include a film,such as a polyethylene film, having a thickness of from about 0.012 mmto about 0.051 mm.

In various constructions, the topsheet can include various woven ornonwoven materials and laminates, which can be stretchable orextensible. In one embodiment, the top sheet is an extensible material.For example, the topsheet can be composed of a meltblown or spunbondedweb of desired fibers, and may also be a bonded-carded web. For example,the topsheet can be made of a substantially hydrophobic material, andthe hydrophobic material may optionally be treated with a surfactant orotherwise processed to import a desired level of wettability andhydrophilicity. In one particular embodiment of the invention, thetopsheet is a nonwoven, spunbond polypropylene fabric composed of about2.8-3.2 denier fibers formed into a web having a basis weight of about22 gsm and density of about 0.06 gm/cc. The fabric can be surfacetreated with an operative amount of surfactant, such as about 0.28%Triton X-102 surfactant. The surfactant can be applied by anyconventional means, such as spraying, printing, brush coating or thelike.

In various constructions, the backsheet can comprise a woven or nonwovenfibrous web layer, which is treated or constructed, partially or wholly,to impart the desired levels of liquid impermeability to selectedregions that are adjacent to or proximate the absorbent retentionportion. For example, the backsheet may include a gas-permeable,nonwoven fabric layer laminated to a polymer film layer which may or maynot be gas-permeable. Other examples of fibrous, cloth-like backsheetmaterials can comprise a stretch thinned or stretch thermal laminatematerial composed of a 0.6 mil (0.015 mm) thick polypropylene cast filmand a 0.7 ounce per square yard (23.8 gsm) polypropylene spunbondmaterial (2 denier fibers). A material of this type has been employed toform the outercover of a HUGGIES® Ultratrim Disposable Diaper, which hasbeen commercially available from Kimberly-Clark Corporation. Thebacksheet can provide the outercover of the article, particularly in thecrotch region. Optionally, however, the article may include a separateoutercover component member, as disclosed herein, which is additional tothe backsheet. The outercover can be joined, for example, to one or moreof the absorbent composite and/or body panels as explained above.

In one embodiment, the retention portion 212, and other components, suchas a transfer layer (not shown) and tissue layers (not shown), are freefloating (unattached) between the back sheet 208 and the top sheet 206,which are secured along only the peripheral edges thereof.Alternatively, the retention portion, transfer layer and othercomponents are minimally attached to one or both of the back sheet 208and top sheet 206. For example, the retention portion can be secured tothe back sheet along an attachment location positioned along thelongitudinal centerline of the retention portion. Alternatively, or incombination with the back sheet connection, the transfer layer orretention portion can be minimally attached to the top sheet. In thisway, the retention portion 212, and other components, do not impede orsubstantially affect the lateral stretchability and extensibility of theabsorbent insert 50 and in particular the top sheet and back sheet, atleast one of which is secured to the body chassis.

In other embodiments, the top sheet is indirectly joined to thebacksheet by affixing the topsheet to intermediate layers, such as thesurge layer or retention portion, which in turn is affixed to thebacksheet. The absorbent insert also may include barrier cuffs, orleakage control shields, formed along the opposite longitudinallyextending edges of the absorbent composite.

In one embodiment, the back sheet 208 is a stretchable, elastic, liquidimpervious member. Alternatively, the back sheet may be liquidpermeable, e.g., when an additional barrier layer is used with theretention portion. In one embodiment, the back sheet 208 is a laminatestructure made of a stretchable, elastic material, such as anelastomeric film, which is laminated to an extensible non-woven materiallayer. It should be understood that the backsheet can be formed from asingle layer or substrate or more than two layers or substrates. Variousbacksheet and topsheet materials are described in U.S. application Ser.No. 10/325,500, filed Dec. 19, 2002, entitled “Disposable UndergarmentWith A Stretchable Absorbent Insert and Method For the Use Thereof,” andassigned to Kimberly-Clark Worldwide, Inc., the Assignee of the presentapplication, the entire disclosure of which application is herebyincorporated herein by reference.

The backsheet may include a micro-porous, “breathable” material whichpermits gases, such as water vapor, to escape from the absorbent garmentwhile substantially preventing liquid exudates from passing through thebacksheet. For example, the breathable backsheet may be composed of amicroporous polymer film or a nonwoven fabric which has been coated orotherwise modified to impart a desired level of liquid impermeability.For example, a suitable microporous film can be a PMP-1 material, whichis available from Mitsui Toatsu Chemicals, Inc., a company havingoffices in Tokyo, Japan; or an XKO-8044 polyolefin film available from3M Company of Minneapolis, Minn. The backsheet may also be embossed orotherwise provided with a pattern or matte finish to exhibit a moreaesthetically pleasing appearance.

In various configurations of the invention, where a component, such asthe backsheet is configured to be permeable to gas while having aresistance and limited permeability to aqueous liquid, the liquidresistant component can have a construction which is capable ofsupporting a selected hydrohead of water substantially without leakagetherethrough. A suitable technique for determining the resistance of amaterial to liquid penetration is Federal Test Method Standard FTMS 191Method 5514, 1978, or an equivalent thereof.

In one preferred embodiment, the backsheet is sufficiently impermeableto liquid and semi-liquid materials to substantially prevent theundesired leakage of waste materials, defined as exudates, including forexample urine and feces. For example, the backsheet member can desirablysupport a hydrohead of at least about 45 centimeters (cm) substantiallywithout leakage. The backsheet member can alternatively support ahydrohead of at least about 55 cm, and optionally, can support ahydrohead of at least about 60 cm, or more, to provide improvedbenefits.

The backsheet and/or outercover also can be extensible. In one preferredembodiment, the backsheet and/or outercover is capable of providing anelongation of at least about 1 cm when subjected to a tensile force of11.8 g/cm, and further provides a substantially permanent deformation ofat least about 20% when subjected to a tensile force of 19.70 g/cm andis then allowed to relax under a zero applied stress for a period of 1minute.

For example, the extensible member can be composed of a necked fiber, acreped fiber, a micro-pleated fiber, polymer films or the like, as wellas combinations thereof. The fabrics may be woven or nonwoven materials,such as spunbond fabrics. One example of a suitable extensible materialis a 60% necked, polypropylene spunbond having a basis weight of about1.2 osy.

As explained above, the backsheet and/or outercover also can beexpandable, for example when it has one or more folds, e.g., one or morez-folds (not shown), or can be both extensible and expandable. The termexpandable as used herein means to enlarge or to increase the extent orarea, lateral and/or longitudinal, thereof, e.g., by unfolding one ormore folds.

The retention portion is preferably made of an absorbent material, whichcan be any material that tends to swell or expand as it absorbsexudates, including various liquids and/or fluids excreted or exuded bythe user. For example, the absorbent material can be made of airformed,airlaid and/or wetlaid composites of fibers and high absorbencymaterials, referred to as superabsorbents. Superabsorbents typically aremade of polyacrylic acids, such as FAVOR 880 available from Stockhausen,Inc. of Greensboro, N.C. The fibers can be fluff pulp materials, such asAlliance CR-1654, or any combination of crosslinked pulps, hardwood,softwood, and synthetic fibers. Airlaid and wetlaid structures typicallyinclude binding agents, which are used to stabilize the structure. Inaddition, various foams, absorbent films, and superabsorbent fabrics canbe used as an absorbent material. Various acceptable absorbent materialsare disclosed in U.S. Pat. Nos. 5,147,343 for Absorbent ProductsContaining Hydrogels With Ability To Swell Against Pressure, 5,601,542for Absorbent Composite, and 5,651,862 for Wet Formed AbsorbentComposite, all of which are hereby incorporated herein by reference.Furthermore, the proportion of high-absorbency particles can range fromabout 0 to about 100%, and the proportion of fibrous material from about0 to about 100%. Additionally, high absorbency fibers can be used suchas Oasis type 121 and type 122 superabsorbent fibers available fromTechnical Absorbent Ltd., Grimsby, Lincolnshire, United Kingdom.

The retention portion can be made of a single or dual layer of absorbentmaterial, and can include various folds. The retention portionpreferably has an hour-glass shape with enlarged end regions.Alternatively, the retention portion can include a folded ormulti-layered configuration. The retention portion preferably has alength substantially equal to, or slightly shorter than, the length ofthe absorbent insert. The retention portion can include one or morebarrier layers attached to the absorbent material. In one embodiment, anupper tissue substrate is disposed adjacent the retention portion.Alternatively, a lower tissue substrate can be disposed adjacent anopposite side of the retention portion, or the tissue can completelyenvelope the retention position.

Referring to FIGS. 4 and 5, the opposite garment side of the end regionsof the crotch member 50, and in particular, the outer, garment sidesurface of the backsheet, are secured to the bodyside surface of theopposed crotch portions 16, 24 of the first and second body panels 4, 6.It should be understood that in alternative embodiments, shown forexample in FIGS. 9-12, the crotch member 50, for example one or theother of the garment side or the body side thereof depending on thefolded configuration thereof, can be secured to the garment side surfaceof the first and second body panels. It should be understood that thecrotch member 50 can be secured using any of the methods of attachmentdescribed above, including for example various adhesives, stitching orother bonding methods. The crotch member can be secured to the bodypanels with any configuration of attachment lines, swirls, patterns,spots, etc., or can be a full and continuous attachment therebetween.

The entire portion of the crotch member 50 overlapping the body panels4, 6 can be attached thereto, or the crotch member can be minimallyattached to the body panels, for example by one or more lines ofattachment formed along the centerline of the absorbent composite, oralong a line adjacent the crotch portions 16, 24 of the body panels, soas to allow the body panels to stretch from side to side and extend fromfront to back, or from the crotch to the waist.

Referring to FIGS. 1-8, the method for fabricating one or moreembodiments of the aforedescribed refastenable absorbent garment isillustrated. Referring to FIGS. 1, 2, 6 and 7, a web 72 of body panelmaterial is cut in a longitudinal machine direction 74 to form a frontand rear body panel web 76, 78. Preferably, the web 72 is cut in asinusoidal wave pattern, which should be broadly interpreted as apattern having peaks 54, 154 and valleys 56, 156, with the patterngenerally defined by a pitch P and an amplitude A, A1. The pattern canbe formed of undulating curves or wave patterns, or can include or bemade entirely of various linear portions.

Each body panel web includes an outer lateral edge 80, 82 and an innercut edge 84, 86. In one embodiment, shown for example in FIG. 3, theinner cut edges 84, 86 of the front and rear body panel webs correspond,or mate such that they have the same shape and amplitude. In such anembodiment, no waste material is generated.

In an alternative preferred embodiment, shown in FIGS. 6-8, the wavepattern defining the first and second cut edges 84, 86 has a first andsecond shape 102, 104 formed on opposite sides of a wave baseline 100,which extends in the longitudinal machine direction approximately halfway between the peaks 54, 154 and valleys 56, 156 of the cut edges. Inthis embodiment, the first shape 102 is different from said second shape104, with each shape having a different curvature. In particular, thefirst shape 102 has a first wavelength L1 and the second shape 104 has asecond wavelength L2. Preferably, the first wavelength L1 is greaterthan the second wavelength L2. In this way, as shown in FIG. 8, thefront body panel 4 can be provided with a different shape than the rearbody panel 6. For example, the undergarment can be configured as a thongshaped undergarment with a relatively narrow rear body panel 6.

In another preferred embodiment, a die cutter 101 is used to cut theweb. The die cutter is configured to form inner cut edges 84, 86 on thefront and rear body panels having different shapes and amplitudes A, A1,as shown for example in FIG. 2. In such an embodiment, a minimal amountof waste material is generated, but it allows for the front and rearbody panels to be specifically shaped to conform to the body of theuser. For example, the shape of the rear body panel web 78 cut edge 86can be provided with lesser amplitude A1 than the amplitude A of thefront body panel web 76. In this embodiment, a minimal amount of wastematerial 42 is produced. In one embodiment, one of the body panels isformed with a wave pattern, or substantially sinusoidal cut edge, whilethe other is configured with a straight cut edge. In various alternativeembodiments, the cut edges can be formed by an oscillating cutter,slitters, water jets, lasers and other known cutting devices.

In the preferred embodiment, each of the front and rear body panel webs76, 78 has a maximum rise (Max R), measured at the peak 54, 154 andforming crotch portion lobes 16, 24 (along the centerline of thegarment), and a minimum rise (Min R), measured at the valley 56, 156.The term “rise,” as used herein, means the measured distance between twoedges, for example the outer edge 80, 82 and the inner cut edge 84, 86of each of the front and rear body panel webs 76, 78 respectively. Thetotal rise of the garment is measured between the outer edges 20, 28 ofthe front and rear body panels, or body panel webs, after the crotchmember is connected thereto. Preferably, one or both of the front andrear body panel webs are shifted in the longitudinal machine direction,as shown to align the maximum rises, or peaks 54, 154, of the front andrear body panels, which also results in the alignment of the minimumrises, or valleys 56, 156, of the front and rear body panels. In apreferred embodiment, the maximum rises, defining lobes 16, 24 of theabsorbent garment, have a profile in plan view that extends outwardlyrelative to the waist edge 20, 28. As shown in FIG. 1, a first andsecond conveyor 101, 103 can simply be spaced apart so as to provide fora longer travel for one of the front and rear body panel webs 76, 78.

Referring to FIGS. 1 and 2, the front and rear body panel webs 76, 78are also separated, or shifted, outwardly relative to one another in thelateral cross-direction 94 so as to form a gap 88 between the cut edges84, 86 of the front and rear body panel webs 76, 78 at the maximum riseformed at the respective peaks 54, 154. In various embodiments, thespacing between the cut edges at the maximum rise of the respectivefront and rear body panels (i.e., the closest spacing between the frontand rear body panels) is preferably between about 1% and about 90% ofthe total rise of the garment, more preferably between about 10% andabout 60% of the total rise of the garment, and most preferably betweenabout 20% and about 40% of the total rise of the garment. In addition,in various embodiments, the spacing between the cut edges at the maximumrise of the respective front and rear body panels is preferably betweenabout 10 mm and about 800 mm, more preferably between about 50 mm andabout 500 mm, and most preferably between about 100 mm and about 300 mm.In an alternative embodiment, the cut edges and the crotch portions ofthe front and rear body panels overlap, and can be secured one to theother. In such an embodiment, the panels can be separated slightly, orcan simply be shifted in the longitudinal direction without any lateralseparation.

In one embodiment, the front and rear body panel webs 76, 78 areseparated such that no portions of either web overlap each other. Forexample, and referring to FIG. 1, in one embodiment, a first pair ofrollers 106 can be angled or twisted to laterally spread the front andrear body panel webs 76, 78 a first amount before they are shifted inthe longitudinal machine direction. A second pair of rollers 108 can beangled or twisted to laterally spread the front and rear body panel webs76, 78 a second amount after they are shifted in the longitudinalmachine direction. Of course, it should be understood that the front andrear body panels can be first shifted in the longitudinal machinedirection the desired amount and then separated in the lateral crossdirection the entire desired amount, or they can also be first separatedin the lateral cross direction the entire desired amount and thenshifted in the longitudinal machine direction. In another embodiment,the portions of the lobes or peaks of the body panels overlap eachother.

After the body panel webs 76, 78 are aligned and separated, regardlessof the order thereof, a plurality of crotch members 50, for exampleabsorbent inserts, are positioned in the lateral cross direction so asto bridge the gaps 88 between the body panel webs 76, 78 at successivepeaks 54, 154 or lobes 16, 24 where the maximum rises of the body panelwebs are aligned at the centerline of the absorbent garment. It shouldbe understood that the term “gap” as used herein includes a “zero”distance between the respective cut edges, wherein the cut edges abutbut do not overlap. The crotch members 50 are secured to the body panelwebs 76, 78 as explained above. It should be understood that the crotchmembers 50 are secured in one embodiment to a bodyside surface 90, 92 ofthe body panel webs 76, 78, although they can also be secured to thegarment side thereof as explained above with respect to FIGS. 9-12. Inone embodiment, the crotch members, for example the absorbent inserts,are assembled offline and are then applied to the front and rear bodypanel webs 76, 78 as those webs are carried by a construction drum 110.

As shown in FIG. 1, the crotch member is preferably rotated using anoffset cam action rotator 112. The rotator includes a plurality oftransfer segments 126, which can have a vacuum applied thereto, thatengage the crotch member 50. Coupler arms 127 connect the transfersegments and a drive ring. The coupler arm 127 includes a cam end havinga cam follower that follows the profile of a cam mechanism. The profileof the cam mechanism can be readily changed to change the desired speedoutput and pitch of the crotch member. In one preferred embodiment, therotator is configured to accelerate the crotch member. If the successivecrotch members 50 are separated by a perforation, the transfer segment126 breaks the perforation as it engages one crotch member and movesaway from the next crotch member, which is engaged by a next transfersegment 126. The rotator rotates the end portion of the transfersegment, preferably approximately 90 degrees, about a radial axis, suchthat the crotch member is oriented in the machine direction as describedabove as the transfer segments are rotated about a horizontal axis 128.Alternatively, the landing material and fastener material are cut andseparated by the transfer segments. The rotator, and the method for theuse thereof, is further disclosed in U.S. Pat. Nos. 5,761,478,5,759,340, and 6,139,004, and U.S. patent application Ser. No.10/038,766, entitled “Apparatus For Applying Discrete Parts to A MovingWeb,” filed Jan. 2, 2002, all of which are assigned to Kimberly-ClarkWorldwide, Inc., the Assignee of the present application, and the entiredisclosures of all of which are hereby incorporated herein by reference.Alternatively, the subassembly can be rotated using a revolving transferroll as shown and described in U.S. Pat. No. 4,608,115, which isassigned to Kimberly-Clark Worldwide, Inc., the Assignee of the presentapplication, and which is hereby incorporated herein by reference in itsentirety.

Referring to FIGS. 1 and 4, after the crotch members 50 are secured tothe body panel webs 76, 78 across the gap 88, the assembly is conveyedon a conveyor 114 to a helical folder 116, wherein the undergarments,and in particular the crotch members, are successively folded such thatthe front and rear body panel webs 76, 78 are positioned in anoverlapping, or overlying relationship, preferably with the outer edges80, 82 aligned. In various alternative embodiments, the body panel webs76, 78 can be secured, for example by bonding, along a lateral crossdirection at the area of minimum rise, or valleys 56, 156 to form theside seam 48. The front and rear body panel webs 76, 78 are then cutalong the lateral cross direction along the seam 48 to form a pluralityof discrete disposable undergarments, each having a front and rear bodypanel 4, 6. Alternatively, the front and rear body panel webs 76, 78 canbe first cut at the area of minimum rise, or valleys 56, 156, and thecrotch member 50 thereafter folded. Various refastenable fasteningmembers can be applied to the front and rear body panels 4, 6 or frontand rear body panel webs 76, 78 before or after the various cutting andfolding operations. In yet another preferred embodiment, as explainedabove, the undergarment can be configured with side seams which securethe front and rear body panels, and refastenable fastening members,which bridge lines of weakness formed in one or the other of the bodypanels.

The elastic elements 36 are preferably incorporated into the web 72 ofbody panel material prior to cutting the web 72 to form the front andrear body panel webs 76, 78. If leg elastics are desired, preferablythey are integrated into the web 72 along a pattern that will follow thecut edge 84, 86 on each of the front and rear body panel webs 76, 78. Ofcourse, it should be understood that the elastics could be secured tothe body panel webs after they are formed by the die cutter, or othercutting operation. In addition, the elastics can be non-continuous andintermittently spaced along the longitudinal direction such that theyare incorporated along only the leg opening portions 18, 26 of the bodypanel webs and body panels.

The pitch (P) of the undergarment can be easily and quickly adjustedwithout the need to change over to new dies. The term “pitch” as usedherein means the distance between any two adjacent things in series, andin particular between the valleys 56, 156 or side edges 30, 32 of thefinished undergarment. In particular, the web 72 of body panel materialis simply stretched or elongated various predetermined amounts before itis cut to form the front and rear body panel webs 76, 78. For example,the largest waist/hip size is provided when the web 72 of body panelmaterial is introduced into the cutting operation, or die cutter, withno elongation or stretch in the longitudinal machine direction. Thesmallest waist/hip size is provided when the web 72 of body panelmaterial is elongated or stretched to its maximum capability, such thatafter the cutting operation, the front and rear body panel webs 76, 78retract to form a garment having a smaller pitch (P) between thevalleys. In one preferred embodiment, the elongation of the body panelmaterial is between about 20% and about 400%, in a more preferredembodiment the elongation is between about 50% and about 300%, and in amost preferred embodiment the elongation is between about 100% and about200%. The final size or pitch of the undergarment is also determined bythe process and positioning of the side seams, and the distancetherebetween.

The rise (R) of the undergarment, measured between the outer edges 20,28, also can be easily and quickly adjusted without the need to changeover to new dies. In particular, the front and rear body panel webs aresimply spaced apart in the lateral cross direction varying amounts,preferably with the gap being less than the length of the crotch member.For example, for a smaller garment having a lesser rise, the front andrear body panel webs 76, 78 are spaced closer together, with a smallergap 88 or by overlapping the body panels, than for a garment having agreater rise.

Preferably, the same crotch member 50 can be used in any of thegarments, regardless of the pitch and rise. In this way, the overallsimplicity and efficiency of the system and method is greatly improved,and there is no need to maintain inserts of different sizes ininventory, or to provide manufacturing capabilities to produce differentsize inserts. Indeed, the preferred embodiment of the method providesfor a system of manufacturing a three-piece disposable undergarment withminimal waste, while providing flexibility to manufacture different sizegarments at minimal cost.

In one use, the body panels 4, 6 are elongated, with the attendantapplication of a tensile force. At the same time, the absorbent insert,which includes in one embodiment an extensible top sheet 206 and astretchable/elastic back sheet 208, stretches or elongates with the bodypanels. The back sheet can be elongated in one embodiment between about20% and about 150%, in another embodiment between about 40% and about125% and in another embodiment between about 50% and about 100%. Since,in one embodiment, the retention portion 212 is free floating, oralternatively is minimally attached to the stretchable top sheet and thestretchable/elastic back sheet, e.g., along the longitudinal centerline, the retention portion 212 does not restrict the elongation of theback sheet 208 and top sheet 206, or the attached body panels 4, 6.

In another use, the folded configuration of the absorbent insert 50 incombination with the absorbent insert being attached to the garment sideof the body panels, allows for the absorbent insert to expand outwardlyas it is insulted by the user. This expansion is effected withoutaffecting the fit to the body of the user. In addition, the lobes of thebody panels 4, 6, which extend over portions of the absorbent insert 50,provide a physical barrier between the absorbent insert and the body ofthe user.

Although the present invention has been described with reference topreferred embodiments, those skilled in the art will recognize thatchanges may be made in form and detail without departing from the spiritand scope of the invention. As such, it is intended that the foregoingdetailed description be regarded as illustrative rather than limitingand that it is the appended claims, including all equivalents thereof,which are intended to define the scope of the invention.

1. A disposable undergarment comprising: an elasticized front body panelcomprising a pair of opposite first side edges, a first waist edge and afirst crotch edge spaced from said first waist edge; an elasticized rearbody panel comprising a pair of opposite second side edges, a secondwaist edge and a second crotch edge spaced from said second waist edge;wherein said crotch edges of each of said front and rear body panel webscomprises at one peak and at least one valley, each of said front andrear body panels having a minimum rise defined between said valley ofeach of said respective front and rear body panels and said first andsecond waist edges respectively, each of said front and rear body panelshaving a maximum rise defined between said peak of each of saidrespective front and rear body panels and said first and second waistedges respectively, wherein said valleys defining said minimum risesform at least in part leg opening portions of said front and rear bodypanels, wherein each peak defining each of said maximum rises is alignedwith a longitudinally extending centerline of the undergarment, whereinsaid crotch edges of said front and rear body panels are spaced apartand form a gap therebetween in a non-overlapping relationship; and acrotch member bridging said gap and having opposite end portionsconnected to said front and rear body panels respectively, wherein saidcrotch member does not cover said valleys defining said minimum rises ofeach of said front and rear body panels.
 2. The disposable undergarmentof claim 1 wherein each of said crotch edges of said front and rear bodypanels includes a curved portion and a linear portion.
 3. The disposableundergarment of claim 2 wherein said crotch edges of said front and rearbody panels are complementary.
 4. The disposable undergarment of claim 1wherein each of said crotch edges of said front and rear body panelsincludes a curved convex shaped portion and a curved concave shapedportion.
 5. The disposable undergarment of claim 1 wherein at least aportion of said leg opening portions are elasticized.
 6. The disposableundergarment of claim 5 wherein at least a portion of said leg openingportions comprises at least one elastic thread disposed adjacent saidcrotch edge of each of said front and rear body panels.
 7. Thedisposable undergarment of claim 1 wherein said crotch member comprisesan absorbent insert.
 8. The disposable undergarment of claim 7 whereinsaid absorbent insert comprises a top sheet, a back sheet and aretention portion disposed between said top sheet and said backsheet. 9.The disposable undergarment of claim 8 wherein said crotch membercomprises a base panel having opposite side edges and at least a pair offolds extending from said side edges of said base panel, wherein said atleast said pair of folds are formed by at least one of said top sheetand said backsheet.
 10. The disposable undergarment of claim 9 whereinsaid at least said pair of folds comprises a pair of first foldsextending inwardly from said side edges of said base panel.
 11. Thedisposable undergarment of claim 9 wherein said crotch member issubstantially C-shaped in cross-section.
 12. The disposable undergarmentof claim 9 wherein said pair of folds each have a garment side surfacesecured to first and second garment side surfaces of said front and rearbody panels.
 13. The disposable undergarment of claim 9 wherein said atleast said pair of folds comprises a pair of first folds connected tosaid side edges of said base panel and a pair of second folds connectedto said first folds along a pair of folding edges.
 14. The disposableundergarment of claim 13 wherein opposite side portions of said crotchmember are each substantially z-shaped in cross-section.
 15. Thedisposable undergarment of claim 9 wherein said retention portion isdisposed only along said base portion and does not form any portion ofsaid pair of folds.